Door closer assembly

ABSTRACT

A door closer assembly configured for replacing a previous door closer assembly and installing using pre-existing mounting holes. The door closer assembly includes a closer having a closer housing and a pair of universal mounting brackets. The closer housing has an abutment surface along an axis of the closer. Each universal mounting brackets has mounting openings aligning with the pre-existing mounting holes. The closer is secured to the universal mounting brackets.

CROSS REFERENCE TO RELATED APPLICATIONS

Not Applicable.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

BACKGROUND

The present disclosure relates to commercial and residential doorclosers and universal mounting brackets thereof that provide for easyinstallation of the closer using pre-existing mounting holes alreadypresent in the door or jamb.

There is a consistent problem of degraded door integrity and complexityin installation when replacing a worn door closer with a new closerhaving a different mounting hole-pattern. Currently, products on themarket have a wide variety of mounting hole-patterns. When replacing adoor closer, the user must purchase a product that has exactly the samehole-patterns, make use of a heavy cumbersome adapter plate (onlyapplicable for some models), or drill and tap new holes in door toaccommodate the mounting hole-pattern of the new closer. Drilling andtapping of mounting holes requires certain equipment and a higher levelof skill than what many non-professional installers possess. Further,installation of a door closer having a different hole-pattern ormounting bracket design often leaves exposed unused holes that areunattractive and that may reduce the strength and structural integrityof the door's mounting surface.

SUMMARY

The various embodiments of the present door closer assembly andassociated methods have several features, no single one of which issolely responsible for their desirable attributes. Without limiting thescope of the present embodiments as expressed by the claims that follow,their more prominent features now will be discussed briefly. Afterconsidering this discussion, and particularly after reading the sectionentitled “Detailed Description,” one will understand how the features ofthe present embodiments provide the advantages described herein.

The present door closer assembly includes a pair of universal mountingbrackets and a closer for replacement of a previously-installed closerand its mounting devices, while utilizing existing mounting pointsalready on the door so that new mounting holes are not required tocomplete the closer installation. The term “universal,” as used inconnection with the mounting brackets described herein, means“attachable to a mounting surface at any of a variety of patterns ofpre-existing mounting points in the mounting surface.” This function isachieved in an embodiment of the disclosure, by providing the mountingbrackets with a combination of mounting openings (holes and/or slots)that may be selectively aligned with any of the variety of patterns ofpre-existing mounting points.

The present door closer assembly provides for do-it-yourself (“DIY”)installation of a low cost universal mounting system that allows theinstaller to use existing mounting hole-patterns for efficient andeffective mounting of the closers. The two universal mounting bracketsof the improved mounting device provide a universal mount capabilitythat is adaptable to align the mounting brackets vertically and thecloser horizontally, making the installation easy and secure. It may beappreciated that the present closer is not limited to being alignedstrictly in a horizontal direction parallel to the floor or the ground,but can be at any angle with respect to the floor or ground.

According to one aspect of the present disclosure, a door closerassembly that is mountable on a mounting surface with one of a pluralityof patterns of pre-existing mounting holes, comprises a closer housinghaving first and second opposed ends, a first universal mountingbracket, and a second universal mounting bracket. The first universalmounting bracket is configured to retain the closer housing at the firstend thereof, and a second universal mounting bracket is configured toretain the closer housing at the second end thereof. Each of the firstand second universal mounting brackets have a plurality of mountingopenings arranged in a pattern in which at least one of the mountingopenings is alignable with at least one of the pre-existing mountingholes in any two or more of the plurality of patterns.

According to another aspect of the present disclosure, a door closerassembly configured for replacing a previous door closer assembly andusing pre-existing mounting holes in the door or the door jamb,comprises a closer having a closer housing and a pair of universalmounting brackets. The closer housing has at least one abutment surfacealong an axis of the closer. The universal mounting brackets are mountedat opposite end portions of the closer housing. Each of the universalmounting brackets has a plurality of mounting openings and a securingportion. Each of the plurality of mounting openings aligns with at leastone of the pre-existing mounting holes, and the securing portion isconfigured for gripping the closer. The closer is slidable along thesecuring portions.

According to yet another aspect of the present disclosure, a method ofreplacing and installing a door closer assembly comprises removing aprevious door closer assembly from a mounting surface on either a dooror a door jamb, orienting a first universal mounting bracket relative toat least a first pre-existing mounting hole in the mounting surface fromthe previous door closer assembly, fixing the first universal mountingbracket to the mounting surface through the at least first pre-existingmounting hole, sliding a closer through the first universal mountingbracket, orienting a second universal mounting bracket relative to atleast a second pre-existing mounting hole in the mounting surface,sliding the closer back towards the first universal mounting bracket,fixing the second universal mounting bracket to the mounting surfacethrough the at least second pre-existing mounting hole, positioning thecloser by sliding the closer between the first and second universalmounting brackets, and securing the closer to the first and seconduniversal mounting brackets at a final position.

BRIEF DESCRIPTION OF THE DRAWINGS

The various embodiments of the present disclosure will be discussed indetail with an emphasis on highlighting the advantageous features. Theseembodiments depict the novel and non-obvious features and associatedmethods shown in the accompanying drawings, which are for illustrativepurposes only. These drawings include the following figures, in whichlike numerals indicate like parts:

FIG. 1 is a front perspective view of a door closer assembly inaccordance with embodiment of this disclosure, the door closer assemblyincluding first and second universal mounting brackets and a closerbody;

FIG. 2 is a cross-sectional view of the first universal mounting bracketand the closer body, taken through the line 2-2 in FIG. 1;

FIG. 3 is a front perspective view of the first universal mountingbracket of FIG. 1.

FIG. 4 is an exploded front perspective view of the door closer assemblyof FIG. 1 with a parallel closer arm;

FIGS. 5A-5I illustrate steps in a method of installing the door closerassembly to a door, with a parallel closer arm attached to a top doorjamb, in accordance with an embodiment of this disclosure;

FIG. 6 is a front elevation view of the door closer assembly with aparallel closer arm, with the closer housing mounted on a door in afirst door-mount installation, with the closer arm attached to a doorjamb;

FIG. 7 is a front elevation view of the door closer assembly mounted ona top door jamb in accordance with a jamb-mount installation, with acloser arm attached to the door; and

FIG. 8 is front elevation view of the door closer assembly, with thecloser housing mounted on the door in a second door-mount installation,with a closer arm attached to the doorjamb.

DETAILED DESCRIPTION

FIG. 1 illustrates one embodiment of the present door closer assembly10. The door closer assembly 10 includes a closer 60 (which may bereferred to as a “replacement closer” if it is used to replace apreviously-installed closer), a first universal mounting bracket 20, anda second universal mounting bracket 40. (The term “universal,” as usedin this disclosure, is defined above.) The universal mounting brackets20, 40 are used to mount and secure the closer 60 to a mounting surface,such as a door or a door frame member, particularly a top door jamb.

The closer 60 includes a closer mechanism (not shown) housed in a closerhousing 61. Commercial and residential door closer mechanisms, and theirfunction/operation/construction, are well known in the market. Thesewell-known closer mechanisms are incorporated herein without furtherelaboration on their typical capabilities, function, and operation.

The first and second universal mounting brackets 20, 40 areadvantageously in an embodiment of this disclosure, mirror images ofeach other. In other embodiments, they may be identical, orsubstantially different from each other. The first and second brackets20, 40 each include a securing portion 22, configured to engage and gripthe closer housing 61. For simplicity, features described for the firstuniversal mounting bracket 20 also apply to the second universalmounting bracket 40.

The closer housing 61 has one or more abutment surfaces 63 that extendoutwardly and run parallel to a longitudinal axis of the closer housing61. In the illustrated embodiment, there are two abutment surfaces 63positioned on opposed sides of the housing 61 and are alignedsymmetrically relative to each other and extending the entire length ofthe closer housing 61. Each of the abutment surfaces 63 can be a ridge,a series of flat surfaces, a curved surface, or any other shape engagingand aligning with the securing portions 22 of the first and seconduniversal mounting brackets 20, 40. The abutment surfaces 63 allow forside-to-side adjustability of the closer 60. The closer housing 61 withthe abutment surfaces 63 can be formed from a casting, such asdie-casting. Thus, no secondary machining is required to produce theabutment surface 63, but can be performed if necessary. The closerhousing 61 can also be fabricated by other means such as joining two ormore housing pieces, and sheet metal forming with minimal or nopost-machining required.

The closer 60 can further include a pair of mounting tabs 64 at oppositeends of the closer housing 61 for first time installations, when theuniversal mounting brackets are not required. The mounting tabs 64 havemounting holes 65 to mount the closer 60 directly to a door, jamb,frame, or other mounting surface. A rotation gear 68 of the closermechanism extends out of the closer housing 61. The location of therotation gear 68 divides the closer into a first portion 66 and a secondportion 67. As shown, the first portion 66 is longer than the secondportion 67. In some embodiments, the long portion 66 can besubstantially equal in length to the short portion 67. The abutmentsurfaces 63 can be discontinuous at or near the rotation gear 63, insome embodiments.

Referring also to FIGS. 2 and 3, the securing portion 22 of the firstand second universal mounting brackets 20, 40 is configured forsupporting and securing the closer housing 61. The securing portion 22can also provide a clamping or biasing force exerted on the closerhousing 61 to retain the closer in the desired final location. Forexample, the securing portion 22 can be a pair of retention arms 26extending from a front surface 28 of a base 21 of each of the first andsecond universal mounting brackets 20, 40. Each retention arm 26 canterminate in a securing lip 27. In the illustrated embodiment, thesecuring lips 27 at the end of each retention arm 26 are facing eachother. The securing lips 27 can be configured to provide a slip-fit forthe closer housing 61, and act as sliding guides for the abutmentsurfaces 63 on the closer housing 61. The engagement between thesecuring lips 27 and the abutment surfaces 63 can also restrain thecloser housing 61 in a direction other than along the longitudinal axisof the closer. The securing lips 27 and/or the corresponding abutmentsurfaces 63 can have a saw-tooth or other configuration to providefurther grip/resistance to movement between the closure housing 61 andthe securing portions 22 of the first and second universal mountingbrackets 20, 40 after the closer 60 is in its final position.

Alternatively, the securing lip 27 can also be present in one retentionarm 26 or neither retention arm. For example, the retention arms 26 canbe spaced apart a distance slightly smaller than or equal to a narrowwidth of the closer housing 61, such that the closer housing 61 forms aninterference fit between the pair of retention arms 26. In someembodiments, the retention arms 26 can act as cantilevered spring armsto grip and secure the closer housing 61.

One or both of the retention arms 26 may be provided with at least oneretention aperture 25, preferably a threaded aperture configured toreceive a mating threaded fixing element 30, which may advantageously bea set-screw, as shown in FIG. 3. The fixing elements 30, when threadedor otherwise installed into their respective retention apertures 25,engage with the closer housing 61. Advantageously, the retentionapertures 25 are set at an inwardly-directed angle (e.g., an acute angleor about 20°-60°, preferably about 30°, relative to the plane of thebase 21 in some embodiments), whereby the fixing elements 30, whenthreaded into their respective apertures 25 so as to bear against thehousing 61, and urge the housing 61 against the front surface 28 of thebase 21.

In the illustrated embodiment, the closer 60 is inserted between theopposed retention arms 26 of each of the universal mounting brackets 20,40 so that the housing 61 can slide freely along its longitudinal axisbetween the securing portions 22 of the first and second universalmounting brackets 20, 40 until the final position is located. The fixingelements 30 (e.g., set screws as shown) are then installed in theirrespective apertures 25 so as to engage against the abutment surfaces 63to force a back surface 69 of the closer housing 60 against the frontsurfaces 28 of the brackets 20, 40, thereby capturing and retaining thecloser 60 in the final position in the first and second universalmounting brackets 20, 40. In the illustrated embodiment, the fixingelements 30 are cone point set screws. However, the fixing elements 30can be any fastener of any suitable size, style, or configuration. Thefixing elements 30 and fixing element apertures 25 may be omitted insome embodiments, or they can be replaced by other securing means tosecure the closer 60 in the final position.

The base 21 of each of the first and second universal mounting brackets20, 40 defines a plurality of mounting openings, such as slots 24 aand/or holes 24 b. The number, configuration, and arrangement of themounting openings are provided so that at least one mounting opening 24,and preferably two more mounting openings, may be aligned withcorresponding pre-existing mounting holes on a mounting surface, such asa door or door jamb, Preferably, at least one of the mounting openingsin each of the universal mounting brackets is an elongate opening orslot 24 a. The alignment of the slots 24 a can be in any direction, butit is advantageous, in some embodiments, to include a slot alignedperpendicular to the longitudinal axis of the closer 60 to allowadjustment in a direction other than the direction the closer 60 canslide along the securing portions 22. The number of mounting openingscan vary and can be arranged in any configuration, interconnected ornon-interconnected, in combination or separately, to align withpre-existing mounting hole patterns 91 (see FIG. 5A) from apreviously-installed closer assembly. Thus, new mounting patterns willnot need to be drilled into the door or jamb. The mounting holes 24 band slots 24 a can be enlarged relative to the thread size and headconfiguration of mounting fasteners, thus providing a greater range ofadaptability for alignment with pre-existing mounting holes in the dooror jamb. In assembly, the brackets can also be inverted (i.e., rotatedupside down) to accommodate the fastening locations. The mounting holes24 b and slots 24 a can advantageously be countersunk, and each canadvantageously have a counter-bored depth. Fasteners from the previouscloser assembly can also be used to secure the first and seconduniversal mounting brackets 20, 40. Other mounting fasteners withappropriate head configuration, thread size, and overall length can alsobe used with the door closer assembly to facilitate installation of theuniversal mounting brackets 20, 40.

The first and second universal mounting brackets 20, 40 can be made ofany suitable rigid or semi-rigid metal or non-metallic material,including, but not limited to, aluminum, aluminum alloy (such as gradeADC12), steel, zinc die-cast, aluminum die-cast, formed sheet metal, anassembly of fabricated metal and/or non-metal components, and plastic ofthe filled and non-filled variety formed by machining, extrusion,molding, or the like.

The universal mounting bracket can be designed with particular draftangles, radii, and fillets to accommodate casting and easy removal fromthe mold. Secondary machining, such as drilling and tapping holes forthe fixing element apertures 25 to receive the fixing elements 30 can beperformed. Inserts can also be used in the fixing element apertures 25to increase installation torque, prevent galling, or add a lockingfeature. The universal mounting brackets can also be fabricated orcasted with features such as alignment aids or identification such as an“A” for the first bracket 20 and a “B” for the second bracket 40.

Referring to FIG. 4, an arm assembly 70 is attached to the rotating gear68 of the closer 60. The arm assembly 70 can include a main arm 71coupled to the rotating gear 68, an arm slide 74 rotatably coupled tothe main arm 71, a connecting rod 77 slidably attached to the arm slide74, and an arm bracket 85 rotatably coupled to the connecting rod 77 andfixed to a mounting surface, such as the door, jamb, frame, or wall.

The main arm 71 has a socket 72 at a first end coupled to the rotatinggear 68 of the closer 60, and a pin 73 at a second end. The socket 72can have a shape closely matching the shape of the rotating gear 68 suchthat the socket 72 is fixed to the rotating gear 68. A fastener andwasher assembly 72 a can prevent the socket 72 from moving out ofengagement with the rotating gear 68.

The arm slide 74 has a socket 75 at a first end rotatably coupled to thepin 73, and an adjustment channel 76 open at a second end anddimensioned to receive a free end 78 of the connecting rod 77, allowingthe connecting rod 77 to slide into the channel 76 from the second endof the arm slide 74. A fastener and washer assembly 75 a can prevent thesocket 75 of the arm slide 74 from moving out of engagement with the pin73. The adjustment channel 76 can be an exposed channel at a bottom ofthe arm slide 74 or a hollowed out channel. The adjustment slot 76 canhave a window 76 a having a width smaller than a width of the slidingportion 78 of the connecting rod 77. A fastener 80 can pass through thewindow 76 a and engage with a threaded hole 81 in the sliding portion 78of the connecting rod 77 to fasten the connecting rod 77 to the armslide 74 when a desired location is determined.

The connecting rod 77 also has a socket 79 at a second end attached to apin 86 of the arm bracket 85. In the illustrated embodiment, the armbracket 85 is a soffit plate for a parallel arm door closerconfiguration. The assembled view of the parallel arm door closerconfiguration is illustrated in FIG. 6. The arm bracket 85 can also be amounting foot that is mounted to a door for a top jamb door closerconfiguration as illustrated in FIG. 7, or mounted to a door jamb for aregular arm door closer configuration as illustrated in FIG. 8.

Referring to FIGS. 5A-5I, one embodiment of a method of replacing andinstalling the door closer assembly to a door is illustrated for a topjamb arm door closer configuration. The method begins by removing aprevious door closer assembly from a top door jamb 90. After removingthe previous door closer assembly, a pre-existing mounting hole pattern91 in the jamb 90 should be visible, as shown in FIG. 5A.

The universal mounting brackets 20, 40 are then oriented and placedrelative to the pre-existing mounting hole pattern 91 in the jamb 90 sothat a mounting hole 24 b or slot 24 a in each of the brackets 20, 40 isaligned with each of at least two of the holes in the pre-existing holepattern 91. One of the universal mounting brackets, preferably theuniversal mounting bracket adjacent to the first (usually longer) side66 of the closer 60, is lightly mounted to the jamb 90 usingpre-existing mounting fasteners or a substitute set, as shown in FIG.5B.

A vertical position of the universal mounting bracket relative to thedoor opening is determined by measurement to ensure proper mountingposition of the door closer assembly on the jamb 90, as shown in FIG.5C. Once the desired vertical position is obtained, the fasteners arefully tightened to fix the universal mounting bracket to the jamb 90.

The first (usually longer) portion 66 of the closer 60 is slid into thesecuring portion 22 of the already-mounted universal mounting bracket asshown in FIG. 5D. The securing portion 22 should hold the closer 60 inplace temporarily, before mounting the other universal mounting bracket.

The other universal mounting bracket is positioned over the pre-existingmounting hole pattern 91 and lightly mounted to the jamb 90 as shown inFIG. 5E. The other universal mounting bracket is held in place whilesliding the closer 60 through its securing portion 22 to align the otheruniversal mounting bracket. FIG. 5F illustrates the second (usuallyshorter) portion 67 of the closer 60 sliding through the securingportion 22 of the other universal mounting bracket.

While still holding the second-mounted universal mounting bracket inplace, the closer 60 is slid back towards the first-mounted universalmounting bracket to allow the fasteners to be fully tightened for thesecond-mounted universal mounting bracket to be secured to the jamb 90,as shown in FIG. 5G.

The second (usually shorter) portion 67 of the closer 60 is then slidback through the securing portion 22 of the second-mounted universalmounting bracket to a desired position. Thus, the relative positionbetween the universal mounting brackets can be adapted to align with thepre-existing mounting holes 91 in the door or jamb 90, while at the sametime being spaced an appropriate distance apart to provide propermechanical support and positioning of the closer 60 relative to the dooror jamb 90. FIG. 5H shows that the horizontal position of the closer 60can be determined by measuring a distance between the rotating gear 68and/or a defined feature or surface of the closer housing 61 and theedge of the door jamb.

Referring to FIG. 5I, the fixing elements 30 (shown as set screws) canthen be tightened against the closer housing 61 to hold the closer 60 inplace and prevent the closer from sliding side to side once theinstaller has positioned the closer 60 in the proper location. The armassembly 70 is then mounted to the closer and to the door to completethe assembly. The preload on the closer 60 can be adjusted to desiredoperating settings, such as door opening angle, backcheck, closing, andlatching speed. The assembled view of the top jamb door closerconfiguration with the arm assembly 70 and mounting foot mounted to thedoor is illustrated in FIG. 7.

The method for replacing and installing the door closer assembly asdescribed in steps 5A-5I can also be applied for replacing a parallelarm door closer configuration illustrated in FIG. 6 using a soffit plateas the arm bracket 85, and can also applied for replacing a regular armdoor closer configuration as illustrated in FIG. 8.

A cover (not shown) can be placed over the closer 60 and universalmounting brackets to enhance cosmetic and overall appearance to thefinal closer installation. Both a covered and non-covered final doorcloser assembly are encompassed by this disclosure.

The assembled view of FIG. 8 illustrates a regular arm door closerconfiguration.

The closer and mounting embodiments described above are improvements tosimplify and reduce the amount of effort and complexity required in theselection and installation of a door closer. This is achieved byproviding a closer assembly and mounting method having a universalmounting device that is installed on the door using the pre-existingdrilled and tapped holes from the previous door closer mounting.Further, this improved closer and mounting method reduces theinstaller's skill level and tool requirements for installation of acloser. This is partially achieved by eliminating the requirement todrill and tap new mounting holes in the door and simplifying the closerselection process.

The use of two separate universal mounting brackets allows universalmounting capabilities for replacing existing door closer assemblies aswell as first time door closer installations. Existing door closerassemblies have fixed mounting hole-patterns and mounting fasteners,which can vary widely. Thus, an improved mounting method and door closerassembly eliminate the requirement to drill and tap new mounting holesto achieve complete installation of the present door closer assembly.

The above description presents the best mode contemplated for carryingout the present invention, and of the manner and process of making andusing it, in such full, clear, concise, and exact terms as to enable anyperson skilled in the art to which it pertains to make and use thisinvention. This invention is, however, susceptible to modifications andalternate constructions from that discussed above that are fullyequivalent. Consequently, this invention is not limited to theparticular embodiments disclosed. On the contrary, this invention coversall modifications and alternate constructions coming within the spiritand scope of the invention as generally expressed by the followingclaims, which particularly point out and distinctly claim the subjectmatter of the invention.

What is claimed is:
 1. A door closer assembly mountable on a mountingsurface with one of a plurality of patterns of pre-existing mountingholes, the door closer assembly comprising: a closer housing havingfirst and second opposed ends; and a first universal mounting bracketconfigured to retain the closer housing at the first end thereof, and asecond universal mounting bracket configured to retain the closerhousing at the second end thereof, each of the first and seconduniversal mounting brackets having a plurality of mounting openingsarranged in a pattern in which at least one of the mounting openings isalignable with at least one of the pre-existing mounting holes in anytwo or more of the plurality of patterns; wherein the first universalmounting bracket and the second universal mounting bracket eachcomprises a securing portion configured to grip the closer housing, thecloser housing being slidable along the securing portions.
 2. The doorcloser assembly of claim 1, wherein the pattern of the mounting openingsin the first universal mounting bracket is a mirror image of the patternof the mounting openings in the second universal mounting bracket. 3.The door closer assembly of claim 2, wherein the patterns of themounting openings include at least one slot.
 4. The door closer assemblyof claim 1, wherein the securing portion comprises a pair of arms, eacharm comprising an extending portion and a securing lip restricting thecloser housing to movement along a longitudinal axis of the closerhousing.
 5. The door closer assembly of claim 4, wherein the pair ofarms form an interference fit with the closer housing.
 6. The doorcloser assembly of claim 5, wherein the at least one fixing element isthreadingly engaged in the securing portion of the first universalmounting bracket and the second universal mounting bracket.
 7. The doorcloser assembly of claim 5, wherein the at least one fixing element isangled inwardly at an acute angle relative to the mounting surface toforce the closer housing against a front surface of the first universalmounting bracket and the second universal mounting bracket.
 8. The doorcloser assembly of claim 5, wherein the at least one abutment surface isa pair of abutment surfaces positioned opposed and aligned symmetricallyrelative to each other.
 9. The door closer assembly of claim 8, whereinthe pair of abutment surfaces extend along an entire length of thecloser housing forming a pair of continuous and unbroken abutmentsurfaces.
 10. The door closer assembly of claim 1, wherein the closerhousing has at least one abutment surface, and the door closer assemblyfurther comprises at least one fixing element pressing against the atleast one abutment surface to secure the closer housing in a finalposition.
 11. The door closer assembly of claim 1, further comprising apair of mounting tabs extending at the opposite ends of the closerhousing.